Forced convection steam assembly

ABSTRACT

A convection oven includes a convection fan assembly and a trough assembly that surrounds a portion of the heating element(s) of the convection fan assembly. Fluid in the trough assembly is heated and turned into steam by the heating element(s) and blown into the cooking cavity of the convection oven by the convection fan of the convection fan assembly. The steam in the cooking cavity provides moisture to the items that are being cooked and/or heated in the cooking cavity.

CROSS REFERENCE TO RELATED APPLICATION AND CLAIM TO PRIORITY

The present application is a continuation of and claims priority to commonly assigned, pending U.S. patent application Ser. No. 15/451,760 filed on Mar. 7, 2017.

BACKGROUND

Generally, a convection oven includes a convection fan that is near one or more heating elements. The heating element heats air which is blown into the cooking cavity of the oven by the convection fan. While the convection fan is useful to heat and/or cook an item within the cooking cavity, the heated air blown into the cooking cavity can make the item very dry. Stand-alone steam systems are very large and costly to integrate into a cooking appliance. For example, a powered boiler is large, expensive, and requires welding and additional electrical power which may require sharing power with the heating elements and/or the convection fan motor. Thus, it is desirable to have a convection oven that has a smaller, less-expensive approach to provide moisture into the cooking cavity to help keep the item in the cooking cavity moist.

SUMMARY OF THE INVENTION

One aspect of the present invention is an oven with a housing defining a cooking cavity. The oven has a door coupled to the housing. The oven has a convection fan assembly with a convection fan and at least one heating element to generate heat and to heat the air in the cooking cavity. The oven also has a trough assembly with a trough tray portion located underneath a portion of the convection fan and the convection fan heating element. The trough assembly also includes a trough supply portion shaped to receive fluid and to direct the fluid to the trough tray portion so that the fluid can be heated and turned into steam by the heating element(s) and blown into the cooking cavity by the convection fan.

Another aspect of the present invention is a convection fan assembly with a steaming device. The convection fan assembly has a convection fan connected to a motor that rotates the convection fan and at least one generally annular heating element coupled near the convection fan. The convection fan assembly also has a trough assembly. The trough assembly has a trough tray located underneath a portion of the convection fan and the generally annular heating element(s). The trough assembly also has a trough supply portion shaped to receive fluid and to direct the fluid to the trough tray portion so that the fluid can be heated by the generally annular heating element(s) and turned into steam, which is blown by the convection fan.

Another aspect of the present invention is a method for providing steam to a convection oven. The method includes forming a trough tray capable of holding fluid while surrounding a portion of the heating element(s) of the convection oven. The method includes forming a trough supply portion shaped to direct fluid to the trough tray. The method also includes adding fluid to the trough tray so that the fluid can be heated by the heating element(s) of the convection oven and forced into the oven cooking cavity by the fan of the convection oven.

These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of an oven according to an embodiment of the present concept;

FIG. 2 is a partial front perspective view of the cavity of the oven shown in FIG. 1 with the baffle covering the convection assembly removed;

FIG. 3 is a front perspective view of the convection fan assembly and trough assembly of the oven shown in FIG. 1;

FIG. 4 is front perspective view of the convection fan assembly and trough assembly shown in FIG. 3 before the trough assembly is situated around a portion of the convection fan assembly;

FIG. 5 is a front view of the convection fan assembly and trough assembly showing a drip valve above a portion of the trough assembly; and

FIG. 6 is a partial cross section showing the convection fan assembly, the trough assembly, and fluid supply along with fluid level(s) in the trough assemblies.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As referenced in the figures, the same reference numerals may be used herein to refer to the same parameters and components or their similar modifications and alternatives. For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the present disclosure as oriented in FIG. 1. However, it is to be understood that the present disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. The drawings referenced herein are schematic and associated views thereof are not necessarily drawn to scale.

With reference to the drawings, an oven 2 includes a cooking cavity 4 and an oven door 6. The oven door 6 can have a handle 8 to assist in the opening and closing of the oven door 6 for access to the cooking cavity 4. The oven 2 can have a number of burners 10 that are controlled by associated burner controls 12. As illustrated in FIG. 2, the cooking cavity 4 can have one or more racks 14 that are supported by rack supports 16.

The oven 2 includes a convection fan assembly 20 that provides heated air to the cooking cavity 4 to heat and/or cook items within the cooking cavity 4. Typically, a baffle (not shown) is placed over the convection fan assembly 20 to prevent contact with the components of the convection fan assembly 20 when the cooking cavity 4 is used. This baffle has apertures that allow air to pass from the convection fan assembly 20 to the cooking cavity 4.

The convection fan assembly 20 includes a mounting plate 32 that allows the convection fan assembly 20 to be coupled to the cooking cavity 4. The convection fan assembly 20 includes a fan blade 34 that is rotated by a motor coupled to a connection 36. A fastener 38 is used to secure the fan blade 34 to the connection 36.

In the illustrated embodiment, the convection fan assembly 20 has a generally annular heating element(s) 30. These heating element(s) 30 are positioned generally near the fan blade 34 but do not inhibit the movement of the fan blade 34. As illustrated in FIG. 6, the fan motor is powered by electrical connection 48, while the heating element(s) 30 are powered by electrical connection 46.

A trough assembly 18 includes a trough tray portion 22 with an interior 28 and a trough supply portion 24, as illustrated in FIGS. 2-6. While the trough tray portion 22 and trough supply portion 24 are shown as a unitary piece in the illustrated embodiment, they can be separate pieces that are positioned relative to each other.

The trough tray portion 22 is shaped to surround a portion of the convection fan assembly 20, as shown in FIGS. 2-6. When the trough tray portion 22 is situated around the convection fan assembly 20, a portion of the heating element(s) 30 is within the interior 28 of the trough tray portion 22.

The trough supply portion 24 has a generally cylindrical tubular design in the illustrated embodiment. However, the trough supply portion 24 can be of any shape, so long as it can direct fluid to the trough tray portion 22. However, in some embodiments the trough tray portion 22 can be manually filled with fluid and/or have a fluid connection directly to the trough tray portion 22 without the need for a trough supply portion 24.

The trough tray portion 22 and the trough supply portion 24 can be made of the same or different materials. The trough tray portion 22 needs to be made of a material that can withstand the heat generated by the heating element(s) 30. Thus, the trough tray portion 22 can be made of metal or a high temperature-resistant ceramic or polymeric material.

A fluid supply system can be used to supply fluid to the trough tray portion 22. As shown in FIGS. 5 and 6, that fluid supply system can be used in connection with the trough supply portion 24. For example, tube end 40 may be positioned over the interior opening 26 of the trough supply portion 24. The tube 42 extends from a valve 44 to the tube end 40, as illustrated in FIG. 6.

As illustrated in FIG. 6, the fluid level 50 can be below the heating element(s) 30. In this arrangement, the heating element(s) 30 can heat the fluid and turn it into steam to be forced into the cooking cavity 4 by rotation of the fan blade 34. Also as illustrated in FIG. 6, the fluid level 50A can actually cover a portion of the heating element(s) 30. Again, in this arrangement, the heating element(s) 30 will heat the fluid and turn it into steam to be forced into the cooking cavity 4 by rotation of the fan blade 34.

The fluid can be water or water with an additive. For example, the additives could include any number of different flavors, such as liquid smoke, liquid garlic, or any other desired flavor.

The valve 44 can be of any type of valve. For example, it can be a drip ball valve, a solenoid valve, or other type of valve.

The valve 44 may be controlled electronically. For example, the valve 44 can be opened or closed based upon any one or combination of factors, including, but not limited to, the humidity in the cooking cavity 4, the fluid level 50, 50A in the trough tray portion 22, timing, steam percent, etc.

The fluid supply can also include a conduction break to prevent heat transfer to the valve 44. In addition, the fluid supply can have multiple outlets for multiple convection fans.

The heating element(s) 30 can be any type of heating element(s). In the illustrated embodiment, the heating element(s) 30 in a calrod burner that can reach a temperature of approximately 700° C. (1292° F.) which will turn the fluid into steam.

It will be understood by one having ordinary skill in the art that construction of the described device and other components is not limited to any specific material. Other exemplary embodiments of the device disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement of the elements of the device as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present device. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present device, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodiments only. Modifications of the device will occur to those skilled in the art and to those who make or use the device. Therefore, it is understood that the embodiments shown in the drawings and described above is merely for illustrative purposes and not intended to limit the scope of the device, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents. 

What is claimed:
 1. A method for providing steam to a convection oven cooking cavity, comprising: placing a trough tray around at least a portion of at least one generally annular heating element that surrounds at least a portion of a fan blade of a convection fan assembly; filling said trough tray assembly with a fluid; and heating said fluid in said trough tray assembly with said at least one generally annular heating element to generate steam to be blown into said cooking cavity of the convection oven by said convection fan assembly.
 2. The method for providing steam to a convection oven cooking cavity of claim 1, wherein: said trough tray assembly includes a trough tray portion having walls that surround at least a portion of said at least one generally annular heating element.
 3. The method for providing steam to a convection oven cooking cavity of claim 2, wherein: said trough tray assembly includes a trough supply portion shaped to receive said fluid and direct said fluid to the trough tray portion.
 4. The method for providing steam to a convection oven coking chamber of claim 3, wherein: said trough tray portion and said trough supply portion are a unitary piece.
 5. The method for providing steam to a convection oven cooking chamber of claim 3, wherein: said trough tray assembly is made from a high temperature-resistant material.
 6. The method for providing steam to a convection oven cooking chamber of claim 5, wherein: said high temperature-resistant material includes a metal.
 7. The method for providing steam to a convection oven cooking chamber of claim 5, wherein: said high temperature-resistant material includes a polymeric material.
 8. The method for providing steam to a convection oven cooking chamber of claim 5, wherein: said high temperature-resistant material includes a ceramic material.
 9. The method for providing steam to a convection oven cooking chamber of claim 1, wherein: said at least one generally annular heating elements is a calrod heater.
 10. A method for providing seam to a convection oven, comprising: placing a trough tray assembly around at least a portion of a heating element that surrounds at least a portion of a flan blade of a convection fan; filling said trough tray assembly with a fluid; and heating said fluid in said trough tray assembly with said heating element to generate steam in the convection oven.
 11. The method for providing steam to a convection oven of claim 10, wherein: said trough tray assembly includes a trough tray portion having walls that surround at least a portion of said heating element.
 12. The method for providing steam to a convection oven of claim 11, wherein: said trough tray assembly includes a trough supply portion shaped to receive fluid and direct it to said trough tray portion.
 13. The method for providing steam to a convection oven of claim 12, wherein: said trough tray portion of said trough supply portion are a unitary piece.
 14. The method for providing steam to a convection oven of claim 12, wherein: said trough tray assembly is made from a high temperature-resistant material.
 15. The method for providing steam to a convection oven of claim 14, wherein: said high temperature-resistant material includes a polymeric material.
 16. The method for providing steam to a convection oven of claim 10, wherein: said fluid is water with an additive.
 17. A method for providing fluid to a steam assembly in a convection oven, comprising: placing a trough tray portion around at least a portion of at least one heating element in a convection fan assembly; placing a trough supply portion above at least a portion of said trough tray portion to receive and direct fluid into said trough tray portion; and supplying a fluid to said trough supply portion so that said fluid can be heated by said at least one heating element to generate steam.
 18. The method for providing fluid to a steam assembly in a convection oven of claim 17, wherein: said fluid supplying step includes positioning at least one valve above said trough supply portion.
 19. The method for providing fluid to a steam assembly in a convection oven of claim 18, wherein: said at least one valve is an electronically controlled valve.
 20. The method for providing fluid to a steam assembly in a convection oven of claim 18, wherein: said fluid supplying step includes a conduction break to prevent heat from traveling to said at least one valve. 